Upon cutting all the profiles and dry assembling everything it was now time to fit the panel inserts.

From the split stock I prepared there was quite a bit of additional work required getting them all to 6mm thickness.

The thicknesser was initially used to get the material to a useable state, it worked well although the timber is very hard. Its previous life as a potato crate certainly seasoned it well, there was absolutely no distortion upon splitting the material.

I changed the cutters upon completion and then wheeled out the drum sander.Starting at 60 grit I worked down to 120 grit to get a satisfactory surface finish and precise thickness.

One this was done it was simply a matter of cutting the panels to suit the openings,

The end panel inserts were ripped down to 130mm wide and about 345mm long.

The side panel inserts because of the different size intermediate piece were wider and obviously longer.

For those budding detectives if you look at the top right panel there is a hole present, this is the panel shown in the previous initial ripping blog.